Patent Grant
10738553
This application is a U.S. National Stage Application filed under 35 U.S.C. § 371 and claims priority to International Application No. PCT/EP2016/055357, filed Mar. 11, 2016, which application claims priority to Great Britain Application No. 1504106.4, filed Mar. 11, 2015, the disclosures of which are incorporated herein by reference.
The present invention relates to high frequency percussion enhanced rotary drilling, and in particular to Resonance Enhanced Drilling. Embodiments of the invention are directed to a device for converting rotary motion into linear motion, an actuator (e.g. a linear actuator) incorporating the device, and apparatus and methods for resonance enhanced rotary drilling incorporating and employing the device in order to improve drilling performance. Further embodiments of this invention are directed to resonance enhanced drilling equipment which may be controllable according to these methods and apparatus. Certain embodiments of the invention are applicable to any size of drill or material to be drilled. Certain more specific embodiments are directed at drilling through rock formations, particularly those of variable composition, which may be encountered in deep-hole drilling applications in the oil, gas mining and construction industries.
Percussion enhanced rotary drilling is known per se. A percussion enhanced rotary drill comprises a rotary drill-bit and an actuator or oscillator for applying impact loading to the rotary drill-bit with low frequency and with a limited control of the impact force. The actuator provides impact forces on the material being drilled so as to break up the material which aids the rotary drill-bit in cutting though the material.
Resonance Enhanced Rotary Drilling is a special type of percussion enhanced rotary drilling in which the oscillations are generated at resonance and at high frequency so as to achieve penetration rate enhancement of the material being drilled. This results in an amplification of the dynamic stress exerted at the rotary drill-bit thus increasing drilling efficiency when compared to standard percussion enhanced rotary drilling.
U.S. Pat. No. 3,990,522 discloses a percussion enhanced rotary drill which uses a hydraulic hammer mounted in a rotary drill for drilling bolt holes. It is disclosed that an impacting cycle of variable stroke and frequency can be applied and adjusted to the natural frequency of the material being drilled to produce an amplification of the pressure exerted at the tip of the drill-bit. A servovalve maintains percussion control, and in turn, is controlled by an operator through an electronic control module connected to the servovalve by an electric conductor.
The operator can selectively vary the percussion frequency from 0 to 2500 cycles per minute (i.e. 0 to 42 Hz) and selectively vary the stroke of the drill-bit from 0 to ⅛ inch (i.e. 0 to 3.175 mm) by controlling the flow of pressurized fluid to and from an actuator. It is described that by selecting a percussion stroke having a frequency that is equal to the natural or resonant frequency of the rock strata being drilled, the energy stored in the rock strata by the percussion forces will result in amplification of the pressure exerted at the tip of the drill-bit such that the solid material will collapse and dislodge and permit drill rates in the range 3 to 4 feet per minute.
There are several problems which have been identified with the aforementioned arrangement and which are discussed below.
High frequencies are not attainable using the apparatus of U.S. Pat. No. 3,990,522 which uses a relatively low frequency hydraulic oscillator. Accordingly, although U.S. Pat. No. 3,990,522 discusses the possibility of resonance, it would appear that the low frequencies attainable by its oscillator are insufficient to achieve enhanced drilling penetration through many hard materials. Moreover, there is no mention what would constitute the oscillator.
Regardless of the frequency issue discussed above, resonance cannot easily be achieved and maintained in any case using the arrangement of U.S. Pat. No. 3,990,522, particularly if the drill passes through different materials having different resonance characteristics. This is because control of the percussive frequency and stroke in the arrangement of U.S. Pat. No. 3,990,522 is achieved manually by an operator. As such, it is difficult to control the apparatus to continuously adjust the frequency and stroke of percussion forces to maintain resonance as the drill passes through materials of differing type. This may not be such a major problem for drilling shallow bolt holes as described in U.S. Pat. No. 3,990,522. An operator can merely select a suitable frequency and stroke for the material in which a bolt hole is to be drilled and then operate the drill. However, the problem is exacerbated for deep-drilling through many different layers of rock. An operator located above a deep-drilled hole cannot see what type of rock is being drilled through and cannot readily achieve and maintain resonance as the drill passes from one rock type to another, particularly in regions where the rock type changes frequently.
Some of the aforementioned problems have been solved by the present inventor as described in WO 2007/141550. WO 2007/141550 describes a resonance enhanced rotary drill comprising an automated feedback and control mechanism which can continuously adjust the frequency and stroke of percussion forces to maintain resonance as a drill passes through rocks of differing type. The drill is provided with an adjustment means which is responsive to conditions of the material through which the drill is passing and a control means in a downhole location which includes sensors for taking downhole measurements of material characteristics whereby the apparatus is operable downhole under closed loop real-time control.
US2006/0157280 suggests down-hole closed loop real-time control of an oscillator. It is described that sensors and a control unit can initially sweep a range of frequencies while monitoring a key drilling efficiency parameter such as rate of progression (ROP). An oscillation device can then be controlled to provide oscillations at an optimum frequency until the next frequency sweep is conducted. The pattern of the frequency sweep can be based on a one or more elements of the drilling operation such as a change in formation, a change in measured ROP, a predetermined time period or instruction from the surface. The detailed embodiment utilises an oscillation device which applies torsional oscillation to the rotary drill-bit and torsional resonance is referred to. However, it is further described that exemplary directions of oscillation applied to the drill-bit include oscillations across all degrees-of-freedom and are not utilised in order to initiate cracks in the material to be drilled. Rather, it is described that rotation of the drill-bit causes initial fractioning of the material to be drilled and then a momentary oscillation is applied in order to ensure that the rotary drill-bit remains in contact with the fracturing material. There does not appear to be any disclosure or suggestion of providing an actuator or oscillator which can import sufficiently high axial oscillatory loading to the drill-bit in order to initiate cracks in the material through which the rotary drill-bit is passing as is required in accordance with resonance enhanced drilling as described in WO 2007/141550.
None of the prior art provides any detail about how to monitor axial oscillations. Sensors are disclosed generally in the US2006/0157280 and in WO 2007/141550 but the positions of these sensors relative to components such as a vibration isolation unit and a vibration transmission unit is not discussed.
Despite the solutions described in the prior art, there has been a desire to make further improvements to the methods and apparatus it describes. It is an aim of embodiments of the present invention to make such improvements in order to increase drilling efficiency, increase drilling speed and borehole stability and quality, while limiting wear and tear on the apparatus so as to increase the lifetime of the apparatus. It is a further aim to more precisely control resonance enhanced drilling, particularly when drilling through rapidly changing rock types.
It is a particular focus of the present invention to provide an improved mechanical actuator for converting rotary motion into oscillations along the axis of rotation. Such oscillatory axial motion is an essential feature of resonance enhanced drilling. Whilst the prior art, and WO 2007/141550 in particular, employ actuators of various types, these are not actuators that have been designed for resonance enhanced drilling, but rather are “off the shelf” components. Although these are satisfactory for the purpose, they are not ideal and an improved actuator specifically designed for resonance enhanced drilling is still desired.
Earlier patent applications of the present inventor have described RED modules comprising “off the shelf” actuators, for example in WO 2012/076401. However, in the art, there is no information about how to design an actuator specifically adapted to resonance enhanced drilling.
It is an aim of the present invention to solve the problems associated with the prior art, as highlighted above. In particular, it is an aim of the present invention to provide a device for converting rotational motion into oscillatory axial motion, which device may be employed in an actuator (a linear actuator) for use in resonance enhanced drilling. It is also an aim to provide an apparatus for resonance enhanced drilling comprising the device and actuator of the invention, and methods of drilling employing the device and actuator of the invention.
Accordingly, the present invention provides a device for converting rotary motion into oscillatory axial motion, which device comprises:
In the present context, axial motion refers to a component of motion parallel to the axis of rotation of the rotary motion. Typically the rotary motion is provided by the rotary drilling motion in the context of resonance enhanced drilling.
It is envisaged that this device may be employed in an actuator which may in turn be employed in a resonance enhanced drilling module in a drill-string. The drill-string configuration is not especially limited, and any configuration may be envisaged, including known configurations. The module may be turned on or off as and when resonance enhancement is required.
The one or more bearings employed in the device are not especially limited provided that they serve to facilitate the relative rotatory motion between the rotation element and the base element. Typically the bearings, although interacting with the rotation and the base elements to impart oscillatory axial motion, do not pass on torque from the rotatory motion. Advantageously, the one or more bearings may selected from a fluid bearing (such as a hydraulic bearing (liquid) or a pneumatic bearing (gas), a plain bearing, a rolling-element bearing (such as ball bearings and/or roller bearings and/or barrel bearings), a magnetic bearing, a jewel bearing and a flexure bearing. In downhole drilling applications, rolling element bearings are preferably used.
The raised and or lowered portions are designed to interact with the one or more bearings in order to transform the rotary motion into oscillatory axial motion. The form of the raised or lowered portions is not especially limited provided that this function is not impaired.
In one embodiment, the raised and/or lowered portions are only present on one of the elements (either the rotation element or the base element) whilst the other element does not possess raised or lowered portions (i.e. is typically planar or flat). In this way the axial distance between the elements can be varied as rotation occurs. In this embodiment, the amplitude of oscillation provided by the device depends on the difference between the raised and/or lowered portions as measured along the axial direction.
In a preferred embodiment there may be raised and/or lowered portions on both elements (both the rotation element and the base element). In this embodiment, the amplitude of oscillation provided by the device depends on the sum of the differences between the raised and/or lowered portions as measured along the axial direction.
Rolling-element bearings are preferred, as they reduce or eliminate slipping between the surfaces of the bearing and the rotation element and the base element, and in doing so, advantageously minimise friction between the bearing and the rotation element and the base element.
Thus, the raised or lowered portions may be in the form of indentations and/or protuberances set into the rotation element and/or into the base element. Typically, but not exclusively, the indentations and/or protuberances may be in the form of ridges (4) and troughs (5) running radially out from the axis of rotation of the rotation element and/or of the base element. Preferably, the raised and/or lowered portions may be in the form of regular, periodic changes in the thickness of the rotation element and/or of the base element, in order to provide regular, periodic axial motion. Preferably in order to reduce stress and improve the life of the device, the raised and or lowered portions may be in the form of smooth changes in the thickness of the rotation element and/or of the base element. Preferably, the raised or lowered portions are arranged in a sinusoidal pattern in the circumferential or tangential direction. The surface(s) of the rotation element and/or the base element may therefore provide the one or more bearings passing thereover with an oscillatory motion in the axial direction in a sinusoidal, or periodic, pattern around the tangent/circumference of the rotation element and/or the base element.
In some embodiments, the raised and or lowered portions may be in the form of a track or groove set into the rotation element and/or into the base element, wherein the track or groove is configured to constrain the one or more bearings. In a preferred embodiment, when the one or more bearings are one or more ball bearings, the track or groove may have a tangential cross-section in the shape of an arc. In a particularly preferred embodiment, the tangential cross-section is in the shape of a circular arc. It will be appreciated that when the tangential cross-section is in the shape of a circular arc, and when viewed along the axis, the track or groove is constricted in width and depth at regular intervals, thereby providing a reduced cross-section area. In this embodiment, the groove or track may be said to harmonic or periodic around the circumferential or tangential direction when viewed along the axis. These embodiments reduce slippage between the surfaces of one or more bearings with the rotation element and/or the base element.
The amplitude of oscillation provided by the device may range from 0.1 mm to 5 mm, preferably 0.2 to 4 mm, more preferably 0.4 to 3 mm, more preferably 0.5 to 2 mm, more preferably 0.7 mm to 1.5 mm, and more preferably 0.8 mm to 1.2 mm. A preferred amplitude is 1 mm.
The rotation element and the base element are not especially limited, provided that the function of the device is not impaired. Typically the rotation element and/or the base element are in the form of a disc or annulus within which the raised and/or lowered portions are set. Typically, both the rotation and base elements are in the form of an annulus into which a track or groove is set having a smooth set of “hills and valleys” which form the raised and lowered portions (see
In an embodiment, the device further comprises a spring. The spring may urge the rotation element and the base element together. The spring may be a toroidal unit with a concertina-shaped wall, preferably a hollow metal can with a concertina-shaped wall. The spring may, for instance, be a disc spring or a Belleville washer.
In an embodiment, where rolling-element bearings are used, the device further may comprise a bearing cage. The bearing cage may be used to ensure the angular positions of each rolling-element bearing relative to another rolling-element bearing do not shift.
The present invention also provides an actuator for use in a resonance enhanced drilling module comprising a device as defined above.
The present invention further provides apparatus for use in resonance enhanced rotary drilling, which apparatus comprises a device or an actuator as defined above.
Typically the apparatus comprises:
The sensors are not especially limited, provided that they are capable of performing the required measurements. In typical embodiments sensor (i) and/or sensor (iv) may comprise a load cell.
Typically, the apparatus further comprises a vibration transmission unit between device or actuator (iii) and sensor (iv). Further typically, the vibration isolation unit and/or the vibration transmission unit comprises a structural spring. The structural spring may be, for example, a toroidal unit with a concertina-shaped wall, preferably a hollow metal can with a concertina-shaped wall. The structural spring may, for instance, be a disc spring or a Belleville washer. In an embodiment, the vibration transmission unit increases the amplitude of vibration provided by the device. In an embodiment, the vibration transmission unit increases the amplitude of vibration to provide an amplitude in the range of 0.5 to 10 mm, preferably 1 to 10 mm, more preferably 1 to 5 mm, and more preferably 1 to 3 mm. Alternatively, the vibration transmission unit increases the amplitude of vibration to provide an amplitude of at least 10 mm, preferably at least 5 mm, more preferably at least 3 mm or more preferably at least 1 mm.
In this arrangement, the positioning of the upper sensor (e.g. a load-cell) is typically such that the static axial loading from the drill string can be measured. The position of the lower sensor (e.g. a load-cell) is typically such that dynamic loading passing from the device or actuator through the vibration transmission unit to the drill-bit can be measured. The order of the components of the apparatus of this embodiment is particularly preferred to be from (i)-(viii) above from the top down.
It is envisaged that this apparatus may be employed as a resonance enhanced drilling module in a drill-string. The drill-string configuration is not especially limited, and any configuration may be envisaged, including known configurations. The module may be turned on or off as and when resonance enhancement is required.
The apparatus gives rise to a number of advantages. These include: increased drilling speed; better borehole stability and quality; less stress on apparatus leading to longer lifetimes; provision of oscillations having higher force and/or frequency; improved robustness, in particular by virtue of the exclusive use of the mechanical components in the device; and greater efficiency reducing energy costs.
The preferred applications are in large scale drilling apparatus, control equipment and methods of drilling for the oil and gas industry. However, other drilling applications may also benefit, including: surface drilling equipment, control equipment and methods of drilling for road contractors; drilling equipment, control equipment and method of drilling for the mining industry; hand held drilling equipment for home use and the like; specialist drilling, e.g. dentist drills.
The invention will now be described in more detail by way of example only, with reference to the following Figures, in which:
As has been mentioned, the device operates by transforming rotary motion into axial motion. It employs a kinematic mechanism, which translates the relative rotary motion between the rotation element and the base element into periodic axial excitation, see
Assuming that the relative rotary speed n is the sum of the rotary speed both sides:
n1+n2
the excitation frequency will be a product between this sum and the number of grooves N,
fa=N(n1+n2)/60
if n1 and n2 are given in rpm.
The excitation amplitude is a half of the difference between a hill and a valley on the track set into the rotation element. It should be noted that here ball bearings are shown for illustration only and any sort of bearing arrangements including the hydrostatic and hydrodynamic can be used.
In an embodiment, the number of grooves (that is, a pair of the raised portion and/or lowered portion on the base element or the rotation element), N, may range from 3 to 100, more preferably 8 to 50, more preferably 10 to 40, more preferably 12 to 30, and more preferably 14 to 20. A preferred number of grooves N is 16. The number of the one or more bearings preferably matches the number of grooves N.
In
It will be appreciated that a particular motor may only provide a limited range of rotational speeds. Thus, for a given number raised portions and/or lowered portions, that is, of grooves N, in conjunction with said particular motor, the range of frequencies may be similarly limited. Therefore, in an embodiment, a plurality of devices may be provided, where the numbers of grooves N associated with each device are different. The plurality of devices may be installed in an apparatus such as a drilling tool, where any one of the devices may be activated at a given time. The devices may be installed in series. When a lower range of frequencies is desired, a device having a low number of grooves N may be activated, and vice versa. A device may be deactivated by preventing relative motion between the rotation element and the base element. In an embodiment, a pin or lock may be used to prevent such motion, but it will be appreciated other means may be used to stop such motion. By providing a plurality of devices in an apparatus, where the numbers of grooves N associated with each device are different, it will be appreciated that a wider range of frequencies is possible, compared to where only one device is provided.
The positioning of the upper load-cell is such that the static axial loading from the drill-string can be measured. The position of the lower load-cell is such that dynamic loading passing from the oscillator to the drill-bit can be monitored. The load-cells are connected to a controller in order to provide down-hole closed loop real time control of the oscillator.
It will be apparent that provided that electrical power is supplied downhole, the apparatus of the embodiments (arrangements) of the invention can function autonomously and adjust the rotational and/or oscillatory loading of the drill-bit in response to the current drilling conditions so as to optimize the drilling mechanism.
During a drilling operation, the rotary drill-bit is rotated and an axially oriented dynamic loading is applied to the drill-bit by the actuator to generate a crack propagation zone to aid the rotary drill-bit in cutting though material.
The device or actuator is controlled in accordance with preferred methods of the present invention. Thus, the invention further provides a method for controlling a resonance enhanced rotary drill comprising a device or actuator as defined above, the method comprising:
The ranges for the frequency and dynamic force are based on the following analysis.
The compressive strength of the formation gives a lower bound on the necessary impact forces. The minimum required amplitude of the dynamic force has been calculated as:
Deff is an effective diameter of the rotary drill-bit which is the diameter D of the drill-bit scaled according to the fraction of the drill-bit which contacts the material being drilled. Thus, the effective diameter Deff may be defined as:
Deff=√{square root over (Scontact)}D,
where Scontact is a scaling factor corresponding to the fraction of the drill-bit which contacts the material being drilled. For example, estimating that only 5% of the drill-bit surface is in contact with the material being drilled, an effective diameter Deff can be defined as:
Deff=√{square root over (0.05)}D.
The aforementioned calculations provide a lower bound for the dynamic force of the device or actuator. Utilizing a dynamic force greater than this lower bound generates a crack propagation zone in front of the drill-bit during operation. However, if the dynamic force is too large then the crack propagation zone will extend far from the drill-bit compromising borehole stability and reducing borehole quality. In addition, if the dynamic force imparted on the rotary drill by the device or actuator is too large then accelerated and catastrophic tool wear and/or failure may result. Accordingly, an upper bound to the dynamic force may be defined as:
SFd[(π/4)D2effUs]
where SFd is a scaling factor greater than 1. In practice SFd is selected according to the material being drilled so as to ensure that the crack propagation zone does not extend too far from the drill-bit compromising borehole stability and reducing borehole quality. Furthermore, SFd is selected according to the robustness of the components of the rotary drill to withstand the impact forces of the device or actuator. For certain applications SFd will be selected to be less than 5, preferably less than 2, more preferably less than 1.5, and most preferably less than 1.2.
Low values of SFd (e.g. close to 1) will provide a very tight and controlled crack propagation zone and also increase lifetime of the drilling components at the expensive of rate of propagation. As such, low values for SFd are desirable when a very stable, high quality borehole is required. On the other hand, if rate of propagation is the more important consideration then a higher value for SFd may be selected.
During impacts of the device or actuator of period τ, the velocity of the drill-bit of mass m changes by an amount Δν, due to the contact force F=F(t):
where the contact force F(t) is assumed to be harmonic. The amplitude of force F(t) is advantageously higher than the force Fd needed to break the material being drilled. Hence a lower bound to the change of impulse may be found as follows:
Assuming that the drill-bit performs a harmonic motion between impacts, the maximum velocity of the drill-bit is νm=Aω, where A is the amplitude of the vibration, and ω=2πf is its angular frequency. Assuming that the impact occurs when the drill-bit has maximum velocity νm, and that the drill-bit stops during the impact, then Δν=νm=2Aπf. Accordingly, the vibrating mass is expressed as
This expression contains τ, the period of the impact. The duration of the impact is determined by many factors, including the material properties of the formation and the tool, the frequency of impacts, and other parameters. For simplicity, τ is estimated to be 1% of the time period of the vibration, that is, τ=0.01/f. This leads to a lower estimation of the frequency that can provide enough impulse for the impacts:
The necessary minimum frequency is proportional to the inverse square root of the vibration amplitude and the mass of the bit.
The aforementioned calculations provide a lower bound for the frequency of the device or actuator. As with the dynamic force parameter, utilizing a frequency greater than this lower bound generates a crack propagation zone in front of the drill-bit during operation. However, if the frequency is too large then the crack propagation zone will extend far from the drill-bit compromising borehole stability and reducing borehole quality. In addition, if the frequency is too large then accelerated and catastrophic tool wear and/or failure may result. Accordingly, an upper bound to the frequency may be defined as:
Sf(D2Us/(8000πAm))1/2
where Sf is a scaling factor greater than 1. Similar considerations to those discussed above in relation to SFd apply to the selection of Sf. Thus, for certain applications Sf will be selected to be less than 5, preferably less than 2, more preferably less than 1.5, and most preferably less than 1.2.
In addition to the aforementioned considerations for operational frequency of the device or actuator, it is advantageous that the frequency is maintained in a range which approaches, but does not exceed, peak resonance conditions for the material being drilled. That is, the frequency is advantageously high enough to be approaching peak resonance for the drill-bit in contact with the material being drilled while being low enough to ensure that the frequency does not exceed that of the peak resonance conditions which would lead to a dramatic drop off in amplitude. Accordingly, Sf is advantageously selected whereby:
fr/Sr≤f≤fr
where fr is a frequency corresponding to peak resonance conditions for the material being drilled and Sr is a scaling factor greater than 1.
Similar considerations to those discussed above in relation to SFd and Sf apply to the selection of Sr. For certain applications Sr will be selected to be less than 2, preferably less than 1.5, more preferably less than 1.2. High values of Sr allow lower frequencies to be utilized which can result in a smaller crack propagation zone and a lower rate of propagation. Lower values of Sr (i.e. close to 1) will constrain the frequency to a range close to the peak resonance conditions which can result in a larger crack propagation zone and a higher rate of propagation. However, if the crack propagation zone becomes too large then this may compromise borehole stability and reduce borehole quality.
One problem with drilling through materials having varied resonance characteristics is that a change in the resonance characteristics could result in the operational frequency suddenly exceeding the peak resonance conditions which would lead to a dramatic drop off in amplitude. To solve this problem it may be appropriate to select Sf whereby:
f≤(fr−X)
where X is a safety factor ensuring that the frequency (f) does not exceed that of peak resonance conditions at a transition between two different materials being drilled. In such an arrangement, the frequency may be controlled so as to be maintained within a range defined by:
fr/Sr≤f≤(fr−X)
where the safety factor X ensures that the frequency is far enough from peak resonance conditions to avoid the operational frequency suddenly exceeding that of the peak resonance conditions on a transition from one material type to another which would lead to a dramatic drop off in amplitude.
Similarly a safety factor may be introduced for the dynamic force. For example, if a large dynamic force is being applied for a material having a large compressive strength and then a transition occurs to a material having a much lower compressive strength, this may lead to the dynamic force suddenly being much too large resulting in the crack propagation zone extend far from the drill-bit compromising borehole stability and reducing borehole quality at material transitions. To solve this problem it may be appropriate to operate within the following dynamic force range:
Fd≤SFd[(π/4)D2effUs−Y]
where Y is a safety factor ensuring that the dynamic force (Fd) does not exceed a limit causing catastrophic extension of cracks at a transition between two different materials being drilled. The safety factor Y ensures that the dynamic force is not too high that if a sudden transition occurs to a material which has a low compressive strength then this will not lead to catastrophic extension of the crack propagation zone compromising borehole stability.
The safety factors X and/or Y may be set according to predicted variations in material type and the speed with which the frequency and dynamic force can be changed when a change in material type is detected. That is, one or both of X and Y are preferably adjustable according to predicted variations in the compressive strength (Us) of the material being drilled and speed with which the frequency (f) and dynamic force (Fd) can be changed when a change in the compressive strength (Us) of the material being drilled is detected. Typical ranges for X include: X>fr/100; X>fr/50; or X>fr/10. Typical ranges for Y include: Y>SFd [(π/4)D2effUs]/100; Y>SFd[(π/4)D2effUs]/50; or Y>SFd[π/4)D2effUs]/10.
Embodiments which utilize these safety factors may be seen as a compromise between working at optimal operational conditions for each material of a composite strata structure and providing a smooth transition at interfaces between each layer of material to maintain borehole stability at interfaces.
The previously described embodiments of the present invention are applicable to any size of drill or material to be drilled. Certain more specific embodiments are directed at drilling through rock formations, particularly those of variable composition, which may be encountered in deep-hole drilling applications in the oil, gas and mining industries. The question remains as to what numerical values are suitable for drilling through such rock formations.
The compressive strength of rock formations has a large variation, from around Us=70 MPa for sandstone up to Us=230 MPa for granite. In large scale drilling applications such as in the oil industry, drill-bit diameters range from 90 to 800 mm (3½ to 32″). If only approximately 5% of the drill-bit surface is in contact with the rock formation then the lowest value for required dynamic force is calculated to be approximately 20 kN (using a 90 mm drill-bit through sandstone). Similarly, the largest value for required dynamic force is calculated to be approximately 6000 kN (using an 800 mm drill-bit through granite). As such, for drilling through rock formations the dynamic force is preferably controlled to be maintained within the range 20 to 6000 kN depending on the diameter of the drill-bit. As a large amount of power will be consumed to drive a device or actuator with a dynamic force of 6000 kN it may be advantageous to utilize the invention with a mid-to-small diameter drill-bit for many applications. For example, drill-bit diameters of 90 to 400 mm result in an operational range of 20 to 1500 kN. Further narrowing the drill-bit diameter range gives preferred ranges for the dynamic force of 20 to 1000 kN, more preferably 20 to 500 kN, more preferably still 20 to 300 kN.
A lower estimate for the necessary displacement amplitude of vibration is to have a markedly larger vibration than displacements from random small scale tip bounces due to inhomogeneities in the rock formation. As such the amplitude of vibration is advantageously at least 1 mm. Accordingly, the amplitude of vibration of the device or actuator may be maintained within the range 1 to 10 mm, more preferably 1 to 5 mm.
For large scale drilling equipment the vibrating mass may be of the order of 10 to 1000 kg. The feasible frequency range for such large scale drilling equipment does not stretch higher than a few hundred Hertz. As such, by selecting suitable values for the drill-bit diameter, vibrating mass and amplitude of vibration within the previously described limits, the frequency (f) of the device or actuator can be controlled to be maintained in the range 100 to 500 Hz while providing sufficient dynamic force to create a crack propagation zone for a range of different rock types and being sufficiently high frequency to achieve a resonance effect.
A controller may be configured to perform the previously described method and incorporated into a resonance enhanced rotary drilling module such as those of the embodiments of the invention, in
The inventors have determined that, the best arrangement for providing feedback control is to locate all the sensing, processing and control elements of the feedback mechanism within a down hole assembly. This arrangement is the most compact, provides faster feedback and a speedier response to changes in resonance conditions, and also allows drill heads to be manufactured with the necessary feedback control integrated therein such that the drill heads can be retro fitted to existing drill strings without requiring the whole of the drilling system to be replaced.
The device, actuator and apparatus of the invention are particularly suited to this downhole configuration, where a high pressure wet environment is typical. Such an environment has proven to be difficult to adapt to when employing magnetostrictive actuators and the like. In contrast, the mechanical actuator of the invention has proven readily adaptable to such conditions.
It is a further aim of the present invention to provide an improved steering system for use in directional drilling, and resonance enhanced directional drilling, which systems and methods provide greater steering accuracy and control than known methods and systems, whilst improving reliability and reducing cost by avoiding heavy and complex equipment.
Thus, in a further aspect, the present invention provides an apparatus for use in directional drilling, which apparatus is as defined in any of the above, and additionally comprises:
In the context of this aspect of the present invention, ‘directional drilling’ means any type of drilling in which the direction of drilling can be changed such that the resulting bore hole (specifically the axis of the bore hole) is not a straight line. This includes any and all types of directional drilling currently known in the art.
Also in the context of this aspect of the present invention, ‘longitudinal’ means: in a direction substantially parallel to the axis of the apparatus itself; and/or substantially parallel to the axis of rotation of the apparatus, the drill assembly, or the drill bit; and/or substantially parallel to the axis of the bore hole in the region where the steering actuator is located.
In operation, one or more steering actuators are turned on, so that the longitudinal force is exerted on one side of the apparatus preferentially. This in turn will expand (or contract) the apparatus preferentially on one side, thus ‘bending’ the apparatus sufficiently to turn the drill bit through a small angle. This deformation will continue until the steering actuator(s) are turned off. In the ‘bent’ configuration, the apparatus will drill through a curved trajectory, determined by the degree of bend created by the actuator(s). Thus, the curvature of the trajectory can be controlled by exerting greater or lesser force through the actuator(s) (i.e. creating greater or lesser ‘bend’ in the apparatus) and the direction may be controlled by selecting one or more actuators on one side of the apparatus so that the force acts asymmetrically to create the required ‘bend’ in a chosen direction.
Alternatively (or in addition) one or more drill bit steering inserts are operated so that they are extended from the face of the drill bit for a portion of the drill bit rotation, and refracted during the remaining part of the rotation. Thus, the extension occurs only within a chosen angle of rotation of the drill bit, such that the insert will contact only a chosen portion of the rock face that is in contact with the drill bit. In this way, the rock face is drilled preferentially at the chosen point of contact with the insert. The drill assembly and bore hole then turns in the direction of the preferential drilling.
The advantage of both of these systems is that they allow a steering in any direction without fitting special tools and without complicated mud motors. Moreover, they both allow much finer control, and can bit switched off as easily and quickly as they are switched on, allowing straight drilling to resume. Access to a full 3-dimensional space downhole becomes possible, in a cost effective and efficient manner. Electronic feedback mechanisms and computer control technology can assist the apparatus in achieving the high degree of precision control that is possible using this system.
The present invention further provides a method of drilling comprising operating an apparatus as defined above. Typically, the present method comprises operating one or more of the steering actuators to thereby cause a desired change in direction of drilling, and/or operating one or more of the steering inserts to thereby cause a desired change in direction of drilling.
The principles of the present invention may be best understood by reference to the following examples. It is to be noted, however that the examples do not limit the invention in any way. The scope of the present invention is limited only by the claims which follow, and within whose scope the invention may be modified.
Mechanical Exciter—Proof of Concept
In order to perform a validation of the concept, an FE (finite element) model was constructed. The model has four main components, a top ring with sinusoidal groves [rotation element (1)], a cage with balls [one or more bearings (3)], a bottom ring (standard bearing ring) [base element (2)] and a compressive spring to hold these three components together. This is shown in
The axial displacement of the top ring is shown in
Experimental Results
A prototype of the mechanical exciter as shown in
An experimental time history of the axial displacement of the motion collector of a nominal speed of 650 RPM is shown in
While this invention has been particularly shown and described with reference to preferred embodiments, it will be understood to those skilled in the art that various changes in form and detail may be made without departing from the scope of the invention as defined by the appending claims.
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| WO2016/142537 | 9/15/2016 | WO | A |
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